Metallic tile manufacture



4 r Dec. 1, 1970 J. c. JUREIT ETA!- 3,544,303

' METALLIC TILE MANUFACTURE Filed April 2, 1968 S m r m a %w mm M Cm J WW J6 m A Q k QM ATTORNEYS United States Patent 3,544,353 METALLIC TILE MANUFACTURE John Calvin Jureit, Coral Gables, and Gilbert T. Coovert,

Hollywood, Fla., assignors to Automated Building Components, Inc., Miami, Fla., a corporation of Florida Filed Apr. 2, 1968, Ser. No. 718,140 Int. Cl. B44c 1/08; B05b 7/00; B44c 1/00 U.S. Cl. 117-26 12 Claims ABSTRACT OF THE DISCLOSURE Sheet metal blanks are corrugated to simulate a plurality of tiles disposed in side-by-side relation. Opposite elongated edges of the corrugated blanks are bent in opposite directions to form flanges for interlocking with adjacent tiles. The blanks are spray coated on the weather side with a bituminous emulsion. Colored granules are gravity fed onto the bituminous coated blank and cover the entire coated surface of the blank. Polyvinyl acetate is spray coated on the bituminous granule coating and the multiple coated blank is placed in an oven maintained at temperatures between 180 and 200 F. and within a relative humidity range of 18-40%. The dried tiles are removed from the oven and cooled.

BACKGROUND OF THE INVENTION The present invention relates to building construction and more particularly to sheet metal tiles having a bituminous-granule-plastic coating, the tiles being employed as weather surfaces as in roofing tiles.

Various types of tiles for use in the building industry have heretofore been manufactured, common of which are wood, asbestos, and asphalt shingles and concrete tiles, as well as a wide variety of clay-based tiles. These tiles sulfer various disadvantages, such as high weight per unit area covered which often requires additional support structure, poor thermal and acoustical insulating properties, high manufacturing costs, etc. To overcome such disadvantages, sheet metal tiles have been formed and covered with a water resistant, usually bituminous, coating. These tiles, however, have been diflicult to form and manufacturing procedures have, in general, been unsatisfactory. Moreover, the bituminous coating often becomes tacky making the application and use of such tiles, particularly in hot humid geographical areas, most difficult.

SUMMARY OF THE PRESENT INVENTION The bituminous-granule-plastic coated sheet metal tile formed by the method of the present invention eliminates these disadvantages and provides a tile having minimum weight per unit area of tile, a high degree of both thermal and acoustical insulation, and a low initial cost, coupled with minimum maintenance throughout its wear life. Additionally, the tile formed by the present method is fireproof, readily available in any desired color, and is inert to acids and alkalis and, accordingly, effectively resists corrosion and deterioration. Moreover, the finished tile provides a rough textured appearance affording a heavy tile look. In general, a rectangular sheet metal blank is stamped to form a series of individual tile simulating corrugations, the axes of the corrugations being normal to the long edges of the blank. The long edges of the blank are bent in opposite directions to form front and rear flanges for overlapping engagement with the flanges of next adjacent tiles. The flanges also provide a nailing surface for securing the tiles to a support structure such as roof rafters.

3,544,353 Patented Dec. 1, 1970 Various coatings are applied to the tile blank thus formed and the tile is treated in accordance with the present invention to thereby provide a tile obtaining the advantages noted above. As a first step in forming the present tiles, the surface of each sheet metal tile blank which will be exposed when the tiles are layed and which is hereinafter referred to as the weather surface is spray coated with a bituminous emulsion. The bituminous coated tiles are then placed on a conveyor for disposition below a hopper containing colored granules which may be colored stone chips whereby the chips fall and adhere to the bituminous coated surface of the blanks. To insure that the chips issuing from the hopper adhere to the weather face of the front and rear flanges of each blank, the blanks are disposed on belts comprising the conveyor which angle each tile such that the front and rear flange faces angle upwardly toward the opening in the hopper whereby the chips issuing therefrom adhere to both the front and rear flange faces and the remaining weather surface of each tile.

The tile blanks are then removed from the conveyor and the bituminous-granule coated surfaces thereof are. sprayed with polyvinyl acetate. This outer coating insures a stable surface which is inherently plastic at all times, thus permitting bending, cutting, and forming operations without damage to the coating. Additionally, this final plastic coating provides a high water penetration resistance and is inert to acids and alkalis, thereby effectively precluding corrosion and deterioration of the finished tile.

The bitumen-granule-plastic coated tile is then placed in an oven and baked at a temperature within the range of -200 F. and in a controlled atmosphere having a relative humidity between 18 and 40%. The baking or drying is conducted over a period of 3 to 6 hours whereupon the tiles are removed and placed in a cooling chamher. The bitumen-granule-plastic coating is then set and the tiles are ready for handling and shipment.

Accordingly, it is a primary object of the present invention to provide an improved method of forming tiles having a sheet metal base for use in the building industry.

It is another object of the present invention to provide an improved method of manufacturing sheet metal blanks having bituminous coatings for forming weather resistant tiles.

It is still another object of the present invention to provide a method of forming a composite building tile comprising a bitumen-granule-plastic coating applied to a sheet metal tile blank.

It is yet another object of the present invention to provide an inexpensive method for forming a lightweight, fireproof building tile which provides a high degree of thermal and acoustical insulation, and a rough textured look affording a heavy, individually laid, tile appearance.

DESCRIPTION OF THE DRAWING FIGURES 2 FIG. 1 is a perspective view of a finished tile formed in accordance with the present invention;

FIG. 2 is a vertical cross sectional view showing a plurality of tiles as applied to roof rafters with portions broken out for ease of illustration; and

FIG. 3 is a schematic illustration of a method of forming the tile.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings and particularly to FIG. 1, a finished tile comprising a sheet metal tile blank having a bitumen-granule-plastic coating applied thereto in accordance with the present invention is illustrated at T. To form the metal base of the finished tile, rectangular sheet metal blanks, preferably 28 US. Standard gauge.

galvanized steel, are stamped to form a series of corrugations indicated at 12 simulating individual tiles disposed in side-by-side relation one to the other as in a roof construction. The elongated edges of the rectangular bank are stamped to extend in opposite directions from and substantially normal to the plane of the blank to form leading and trailing edge flanges 14 and 16, respectively, with trailing flange 16 having a narrow additional lip 17 projecting at right angles therefrom.

With the foregoing general tile configuration, the finished tiles may be readily applied to support structures, such as the roof framework illustrated in FIG. 2. To prepare the roof framework to receive the tiles, battens 18 are spaced along and nailed to the outer edges of rafters 20, battens 18 extending between adjacent rafters 20. By properly spacing battens 18 along the roof, the trailing flange 16 of each tile butts the forward face of a batten 18 and the forward portion of each tile extends over the next adjacent lower batten with the rear face of leading flange 14 facing the forward face of the latter batten. The leading flange 14 overlies the trailing flange 16 of each of the next lower tiles and the tiles are secured to the roof structure, preferably by nails 22 driven into battens 18 through the leading flange 14 of the overlying tiles and through the trailing flange 16 of the underlying tiles. In this manner, the finished tiles form a continuous surface from eaves to peak with the coated weather side thereof simulating a roof tile construction formed of individual tiles.

In accordance with the present invention, three layers of coating material, i.e., a layer of water-bound bituminous emulsion, a layer of colored chips or granules, and a layer of plastic (polyvinyl acetate), are applied to the weather surfaces of the metal tile blanks and the composite tile is then treated in a novel manner to form a finished tile having the advantages noted previously. To apply a .first coating of water-bound bituminous emulsion, hereinafter referred to as mastic, the stamped sheet metal tile T is placed on a stand 24 and angled upwardly by a wire rack 26 to elevate the forward edge 14 of the tile such that the complete weather surface of the tile in"- cluding the forward faces of flanges 14 and 16 can be conveniently coated with the mastic. The mastic coating is applied within a booth 28 which is illustrated as turned 90 degrees from its actual position relative to the conveyor 40. A spray gun 30, preferably having a quarter inch diameter nozzle, is supplied with mastic from a pressure pot 32 at a pressure within a range of 55-75 p.s.i.g. as by a suitable pressure source indicated at 34. This nozzle size and spray pressure range has afforded excellent results considering the consistency of the mastic. About to 7 passes of the spray gun over the weather surface of the tile with a slightly heavier coating applied to the bent shoulder portion of the tile between the larger surface thereof and the leading edge flange 14 provides suflicient mastic along the full weather surface of the tile for retaining the chips and to form a base for the plastic coating.

Once coated with mastic, tiles T are automatically and immediately removed from spray booth 28, be means not shown and disposed on upper and lower belts 36 and 38 respectively of a chain driven conveyor generally indicated at 40. The belts 36 and 38 are driven in the same direction about pulleys 37 and 39 respectively by a motor M driving a chain 41. connecting between the motor M and the pulleys in a manner known to the art. The upper belt 36 is spaced rearwardly of the lower belt 38 and the tiles T are disposed on the belts with the leading flanges 14 overlying the upper belt 36 and the trailing flange 16 and lip 17 overlying the lower belt 38. Thus the upper surface of block 36 is inclined such that the weather surface of tile T including the front faces of leading and trailing flanges 14 and 16, respectively, angle upwardly. A hopper 42 containing granules or chips 44 is suitably 4 supported above. conveyor I .40 and .has a lgwer opening 43 extending transversely of conveyor 40 a distance corresponding to the length of the tiles. A hopper gate 46 is pivoted below the opening between an open position, permitting chips 44 to feed from hopper 42, and a closed position by a suitable operator indicated at .48. Operator 48 can comprise any suitable gate control mechanism which can be actuated by a switch sensing the passing of the tiles below hopper '42 and may comprise a solenoid operated air valve controlling a pneumatic piston, the solenoid being controlled by a switch 50. As each emulsion coated tile advances along the conveyor to a position below opening 43, switch 50 actuates operator 48 whereby door 46 is moved to the open position permitting chips 44 to feed downwardly by gravity and to completely cover the weather surface of the emulsion coated tile. As each tile passes beyond opening 43, switch 50 actuates operator 48'to colse gate 46. A tray is disposed below conveyor 40 and beneath hopper 42 to collect for reuse the chips which do not adhere to the emulsion coated tile. If desired, an operator may manually apply chips to those portions of the tile not fully covered by the foregoing hopper chip feed system.

The chips herein employed are preferably #9 granules comprising crushed slate, gravel, brick or the like, which are color coated as desired and commercially available from the 3 M Company. Preferably, only those #9 chips which are sifted through a #8 Tyler Standard Screen are utilized. These chips may be provided with any desired color coating by permanently bonding a pigment thereto by a firing process which is well known in the roofing industry. Color coated crushed stone or natural rock, such as natural colored granite chippings, diabase, argillite and the like, may also be employed if desired. It has been found that chips containing alkaline soluble silicates provide emulsion-chip adhesion-problems and that reemulsification occurs when the pH factor is too high. The chips are accordingly washed in a solution having a pH factor between 5.5 and 8.3.

The bituminous-chip coated tile is removed from conveyor 40 and disposed on a support 54 within a spray booth 56, support 54 being mounted on a stand 58. A mixture of polyvinyl acetate and water, preferably of equal proportions, is sprayed onto the granule-bituminous coated surface of the tile by means of a spray gun.60. The polyvinyl acetate-water or plastic mixture is supplied from a pressurized tank 62 connected with a pressure source 64. This final coating is sprayed evenly over the tile avoiding heavy overlaps which might cause shading on the finished tile when dry. Also, minimum atomizing pressure is employed in applying the plastic coating to avoid separating the mastic from the steel causing exposure of the bare metal on the weather surface. The bituminouschip-plas'tic coated tiles are then placed on a drying stand 66 mounted on a dolly 68. Stand 66 comprises a pair of longitudinally spaced main supports 70 from which a plurality of vertically spaced rods 72 project at upwardly inclined angles on opposite sides thereof. The multiple coated tiles are then placed on rods 72 forming superposed spaced racks of tiles with the uncoated undersurfaces thereof bearing on rods 72 whereby the. upper coated surfaces of the tiles are not disturbed.

When stand 66 is fully loaded with thebituminouschip-plastic coated tiles, it is rolled into an oven 74 wherein the tiles are dried and baked. It has been found that drying the tiles in the oven at a temperature within a range of -200 F. for a period of three to six hours with a humidity controlled to within a range of 1840% and preferably between 18-25% obtains a coating on the sheet metal tiles which provides excellent water penetration resistance and a firm coating set facilitating subsequent tile handling. The oven may be of the electrical resistance heating type, as indicated by the coils 76, with the humidity being controlled by a humidifier 78 located at the top of oven 74 adjacent an air inlet opening 80. A fan 82 forces the humidity controlled air to circulate in and about the tiles T on stand 66 and it has been found that a forced air heating system supplying 3000 cu. ft. per minute and 400,000 B.t.u. per hour is satisfactory to obtain the above-noted results.

After drying at the above-noted temperature and humidity conditions for a period of time within three to six hours, stand 66 is rolled from oven 74 and located within a cooling chamber 84. It will be noted that tile curing continues after the tile is made, even after installation, and that the forced draft cooling assists the initial setting of the mastic, thereby further facilitating subsequent tile handling. To this end, cooling chamber 84 includes a suitably driven fan 86 forcing air through inlets 88 in and about tiles T on rack 66 and through an outlet 90 located at the top of chamber 84. When the tiles are cooled, the coated surface thereof is sutficiently firm as to resist reasonable pressures applied thereagainst. The tile is now ready for use as in a roof installation illustrated in FIG. 2 and hereinbefore described.

Accordingly, it is seen that the objects of the present invention are fully accomplished in that the foregoing method provides a sheet metal tile which is readily and easily manufactured, which effectively simulates tile installations comprised of individually formed tiles, and provides an aesthetically pleasing heavy tile appearance having improved weather resistant characteristics. Moreover, the tile thus formed is fireproof, low in weight, cost and maintenance, provides excellent thermal and acoustical insulation, and is easily installed. Additionally, the final polyvinyl acetate plastic coating insures a stable surface which is inherently plastic at all times, thus permitting bending, cutting, and other forming operations without damage to the coating, thereby insuring a permanent water resistant tile. Additionally, this plastic coating is inert to acids and alkalis and therefore provides a deterioration and corrosion resisting surface insuring long tile life.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

What is claimed and desired to be secured by United States Letters Patent is:

1. A method of making a composite tile comprising coating at least one side of a sheet metal blank with a bituminous emulsion, applying a plurality of granules to the bituminous coating before the latter has set to cover substantially the entire surface area of the emulsion coated blank, applying a coating of plastic material to cover substantially the emulsion-granule coating and baking the coated tile at temperatures within a range between 180 and 200 F.

2. A method according to claim 1 including baking the tile within said temperature range for a period of time within a range of from 3 to 6 hours.

3. A method according to claim 1 including the step of controlling the relative humidity of the baking atmosphere to within a range of 18-40% 4. A method according to claim 1 including the step of controlling the relative humidity of the baking atmosphere to within a range of 1825 5. A method according to claim 1 wherein the step of baking the coated tile includes passing heated air over the coated tile to provide a forced draft air flow.

6. A method according to claim 1 wherein the step of applying the granules includes gravity feeding the granules onto the emulsion coated blank and collecting the granules overflowing from the coated tile for reuse.

7. A method according to claim 1 including the step of cooling the coated tile after it has been baked by circulating cooling air about the tile.

8. A method according to claim 1 wherein the steps of applying the emulsion and plastic coatings include spraying the emulsion on the metal blank and spraying the plastic material on the emulsion-granule coating.

9. A method of making a composite tile comprising coating at least one side of a sheet metal blank with a bituminous emulsion, applying a plurality of granules to the bituminous coating before the latter has set to cover substantially the entire surface area of the emulsion coated blank, applying a coating of plastic material to cover substantially the emulsion-granule coating, baking the tile, and controlling the relative humidity of the baking atmosphere to within a range of 18 to 40%.

10. A method according to claim 9 including the step of cooling the coated tile after it has been baked by circulating cooling air about the tiles.

11. A method according to claim 9 including controlling the relative humidity of the baking atmosphere to within a range of l8-25%.

12. A method according to claim 9 wherein the step of applying the granules includes gravity feeding the granules onto the emulsion coated blank and collecting the granules overflowing from the coated tile for reuse.

References Cited UNITED STATES PATENTS 2,111,761 3/1938 Eckert 11730 2,112,194 3/ 1938 Harshberger l17-30 2,610,928 9/1952 Greider et al 11730 X 2,749,250 6/1956 Christensen et al. 117-30 X 2,775,532 12/ 1956 Sallie et a1 117-32 X 2,787,557 4/ 1957 Christensen et a1. 11730 3,015,635 1/1962 Bradley et al 117135 X 3,098,698 5/1963 Wilson 117--135 X 3,140,195 7/ 1964 Nagel 117-30 X WILLIAM D. MARTIN, Primary Examiner P. F. ATTAGUILE, Assistant Examiner U.S. Cl. X.R. 

